Self-Adhering Disposable Headwear Liner

ABSTRACT

A self-adhering, disposable headwear liner assembly having a topsheet layer, an absorbent core layer and a moisture barrier layer non-adhesively joined to each other, and a plurality of straight channels extending through the topsheet layer and the absorbent core layer and extending partially into the moisture barrier layer, wherein the topsheet layer, the absorbent core layer and the moisture barrier layer each comprise fibers and the fibers of adjacent layers are mechanically interlocked to join the topsheet layer to the absorbent core layer and the absorbent core layer to the moisture barrier layer; and an adhesive layer joined to the moisture barrier layer capable of securing the liner to the internal band of headwear.

BACKGROUND OF THE INVENTION

This invention relates generally to the field of headwear liners or sweatbands, and more particularly to such headwear liners that are temporarily affixed to the forehead or sweatband area of a hat, visor, helmet or other type of headwear, the liner being formed of an absorbent material to absorb perspiration, oils, sunscreens, cosmetics or the like.

Many types of headwear have internal bands that encircle the wearer's head, usually resting on the forehead. For example, in a baseball cap, the internal band is positioned around the base of the crown with its lower edge substantially even with the bill of the cap. These permanently mounted bands easily become soiled over time, especially when the headwear is worn for sports, manual labor or other types of energetic behavior. While certain headwear is washable, many types are not, and thorough cleaning of washable headwear is difficult. It is known to affix disposable liners or sweatbands inside the headwear, usually with an adhesive that is sufficiently strong to retain the disposable liner in the headwear but which allows the disposable liner to be removed and replaced when it becomes excessively soiled.

Examples of sweatbands or sweatband liner devices for headwear are shown in U.S. Pat. No. 1,986,312 to Wilson, U.S. Pat. No. 2,003,886 to Hoffeld, U.S. Pat. No. 4,274,157 to Boden, U.S. Pat. No. 4,393,519 to Nocastro, U.S. Pat. No. 4,394,782 to Wasson, U.S. Pat. No. 4,406,021 to Bloom, U.S. Pat. No. 4,468,817 to Nunnery et al., U.S. Pat. No. 4,502,156 to Wishman, U.S. Pat. No. 4,547,903 to Brown et al., U.S. Pat. No. 4,630,317 to Brown et al., U.S. Pat. No. 4,833,734 to Der Estephanian, U.S. Pat. No. 4,856,116 to Sullivan, U.S. Pat. No. 4,941,210 to Konucik, U.S. Pat. No. 4,947,488 to Ashinoff, U.S. Pat. No. 4,949,404 to Fekete, Sr., U.S. Pat. No. 5,022,095 to Fleury, U.S. Pat. No. 5,025,504 to Benston et al., U.S. Pat. No. 5,046,196 to Sullivan, U.S. Pat. No. 5,058,210 to Tivis, U.S. Pat. No. 5,088,126 to Mathis, U.S. Pat. No. 5,317,761 to Piche, U.S. Pat. No. 5,432,955 to Plotka et al., U.S. Pat. No. 5,553,326 to Moore, U.S. Pat. No. 5,566,395 to Nebeker, U.S. Pat. No. 5,613,248 to Young, U.S. Pat. No. 5,632,046 to Green et al., U.S. Pat. No. 6,477,715 to Shin, and U.S. Pat. No. 6,738,985 to Hahn et al.

It is an object of this invention to provide disposable, self-adhering liners with improved construction that fit virtually all headwear for adults and children. It is an object of this invention to provide a removable, self-adhering and disposable headwear liner that has an improved construction such that the absorption and evaporation efficiency and comfort of the liner are increased.

SUMMARY OF THE INVENTION

The self-adhering and disposable headwear liner or sweatband is a band-shaped assembly that is adapted to be temporarily mounted onto the permanent internal band of headwear, or directly onto a forehead or forefront portion of headwear, such as caps, hats, visors, helmets or the like. The liner is a multi-layer assembly comprising in a preferred embodiment a topsheet layer, an absorbent core layer, moisture barrier layer, an adhesive layer, and a release layer. In an alternative embodiment the adhesive layer may be replaced by a double-sided tape layer. In another alternative embodiment an adhesive layer may be positioned on the both sides of the moisture barrier layer. The absorbent layer is significantly thicker than the other layers, as this layer also provides cushioning for comfort. The topsheet layer possesses high wicking properties, such that the topsheet layer itself remains relatively dry and moisture absorbed into the absorbent core layer is separated from the user's skin.

The topsheet layer, the absorbent core layer and most preferably the moisture barrier layer are assembled into a cohesive unit by a punch-bonding technique, whereby a punch having a plurality of post members creates a plurality of spaced, straight, open channels, holes or bores extending completely through the topsheet layer and the absorbent core layer and partially through the moisture barrier layer. The layers are thus bonded together, the punching technique resulting in the fibers or materials of each adjacent layer becoming mechanically interlocked and intertwined. With this method of manufacture, no adhesives which might interfere with the absorption efficiency of the liner are required to join the layers, the adhesive layer being present only to adhere the liner to the headwear. In an alternative embodiment, only the topsheet layer and the absorbent core layer are punch bonded together, the moisture barrier layer being adhesively joined to the absorbent core layer.

The channels created in the liner provide conduits for better and more rapid absorption of perspiration and other liquids, since the channels allow for direct passage of moisture into the interior and lower portions of the absorbent layer. The channels also provide conduits for better and more rapid evaporation of perspiration and other liquids from the headwear liner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is cross-sectional view of an embodiment of the headwear liner, wherein the topsheet layer, absorbent core layer and moisture barrier layer are punch-bonded together, and the adhesive layer is applied to the underside of the moisture barrier layer.

FIG. 2 is a cross-sectional view of an alternative embodiment of the headwear liner, wherein the topsheet layer, absorbent core layer and moisture barrier layer are punch-bonded together, and a double-sided tape member is joined to the underside of the moisture barrier layer.

FIG. 3 is a cross-sectional view of an alternative embodiment of the headwear liner, wherein the topsheet layer and absorbent core layer are punch-bonded together, and the moisture barrier layer is adhesively bonded to the absorbent core layer.

FIG. 4 is a view of the headwear liner applied onto the interior band of headwear.

FIG. 5A is a view of self-encircling headwear liner, shown in the disconnected configuration.

FIG. 5B is a view of the self-encircling headwear liner of FIG. 5A, shown in the connected configuration.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, the invention will now be described in detail with regard for the best mode and the preferred embodiment. In a broad sense, the invention is a disposable headwear liner or sweatband adapted to be temporarily attached within headwear such that the liner makes direct contact with the wearer to absorb perspiration, oils, sunscreen, cosmetics or other such liquids, referred to herein generally as moisture. In this manner the original internal band of the headwear is protected from soiling and the temporary liner may be removed and replaced when it becomes excessively soiled. As used herein, the bottom or underside of the liner is to be taken to mean the side of the liner that is adhered to the headwear and the top or upper side of the liner is to be taken to mean the side of the liner that remains exposed after attachment of the liner to the headwear and which contacts the user's skin. The thicknesses of the layers in the drawings are for illustrative purposes and are not to scale.

As will be described in more detail, the preferred embodiment is a self-adhering, disposable headwear liner assembly 13 having a topsheet layer 30, an absorbent core layer 50 and a moisture barrier layer 34 non-adhesively joined to each other, and a plurality of well-defined, straight, open bores, holes or channels 51 extending through the topsheet layer 30 and the absorbent core layer 50 and extending partially into the moisture barrier layer 34, wherein the topsheet layer 30, the absorbent core layer 50 and the moisture barrier layer 34 each comprise fibers and the fibers of adjacent layers are mechanically interlocked to join the topsheet layer 30 to the absorbent core layer 50 and the absorbent core layer 50 to the moisture barrier layer 34, and an adhesive layer 35 joined to the moisture barrier layer 34 capable of securing the liner 13 to the internal band 10 of headwear 12.

The liner 13 is an elongated, generally rectangular, flexible member, the edges and sides of which may be straight, curved or of varying configuration and having angled or rounded corners. The dimensions of the liner 13 may vary, but representative and non-limiting dimensions for a suitable liner 13 may be approximately twelve inches in length, approximately one to 1.5 inches in width and one eighth to one quarter inches in thickness. The liner 13 may be longer, shorter, wider, narrower, thinner or thicker than these dimensions.

As seen in FIG. 1, the preferred embodiment of the disposable headwear liner 13 comprises a topsheet layer 30, an absorbent core layer 50, a non-absorbent moisture barrier layer 34, an adhesive layer 35, and a removable release layer 36. To adhere the liner 13 to headwear 12, the release layer 36 is removed to expose the adhesive layer 35, and the liner 13 is pressed against the internal band 10 of the headwear 12 or pressed against the forward portion of headwear 12 not having an internal band, as shown in FIG. 4.

The flexible topsheet layer 30 is liquid permeable and possesses high moisture wicking characteristics, and is preferably non-moisture absorbing. The topsheet layer 30 is significantly thinner than the absorbent core layer 50. The topsheet layer 30 may be composed of many suitable natural or synthetic materials, such as polypropylene (PP) or cotton for example. A preferred embodiment for the topsheet layer 30 is a spunbound (S) non-woven layer of polypropylene. Other suitable materials include but are not limited to polyester (PET) spunbound nonwoven, PP meltblown (M) nonwoven, SMS nonwoven, SMMS nonwoven, wetlaid nonwoven, carded thermalbond nonwoven using PP, PET, rayon, cotton or other fibers alone or in combination, carded spunlace nonwoven using PP, PET, rayon, cotton or other fibers alone or in combination. The basis weighting of the topsheet layer 30 is preferably from 10 gsm to 50 or more gsm, and a gsm of 20 has been found to be suitable. Because of its excellent moisture wicking properties, the topsheet layer 30 remains drier than absorbent core layer 50 since the moisture passes through the topsheet layer 30 rather than being absorbed therein.

The flexible absorbent core layer 50 is significantly thicker than the other layers, preferably being from 50 to 500 or more gsm, with a gsm of 185 having been found to be suitable. The absorbent core layer is highly absorbent of liquids. A preferred embodiment for the core layer 50 is a cellulosic fluff pulp. Other suitable materials include but are not limited to cotton fiber, linters, recycled textile fiber, super-absorbent filler, a combination of these materials, or any of various nonwovens made with a combination of these fibers. The absorbent core layer 50 may be composed of a single layer or of multiple layers of individual absorbent layers of identical or different materials. The absorbent core layer 50 is preferably composed of a material and structure such that there is no or only minimal swelling of the absorbent core layer 50 when it is saturated with moisture.

The flexible moisture barrier layer 34 is non-absorbent and non-permeable to liquids, moisture and/or moisture vapor. The moisture barrier layer 34 also provides structural integrity to the assembled liner 13, being composed of a flexible material such that the moisture barrier layer 34 is inherently stronger and more stable than the topsheet layer 30 and the absorbent core layer 50. A preferred embodiment for the moisture barrier layer 34 is a polyethylene (PE) film with a basis weight of 25 gsm, although gsm's of between 10 and 50 or more may be suitable. Other suitable materials include but are not limited to PP film, low density PE film, high density PE film, and polylactic acid film.

In this embodiment the adhesive layer 35 is an adhesive applied to the underside of the moisture barrier layer 34 and may comprise any adhesive capable of joining the liner 13 to the headwear internal band 10 in a strong yet releasable manner such that the liner 13 will not self-detach yet may be easily removed and replaced. The adhesive must be suitable for use in high temperature and high-moisture environments foreseen likely to occur during use of the headwear 12 in sporting events and the like. Many pressure sensitive adhesives, contact adhesives or hot melt adhesives possessing the required characteristics will be known those of ordinary skill in the art.

The removable release layer 36 is a temporary protective layer for the adhesive layer 35 and is removed and discarded prior to application of the liner 13 to the headwear 12, as shown in FIG. 4. Any of the common paper or polymer film members coated with a release agent, such as silicone, may be utilized.

The topsheet layer 30, absorbent core layer 50 and moisture barrier layer 34 are most preferably connected together without adhesives using a punch bonding technique of manufacture. In punch bonding, a plurality of small pins or posts are pressed into and through the layers, whereby the fibers composing adjacent layers become mechanically interlocked or intertwined and secure the adjacent layers against separation. The posts pass completely through the topsheet layer 30 and the absorbent core layer 50, while preferably passing only partially into but not completely through the moisture barrier layer 34. The posts possess a minimum diameter of preferably from about 2 mm to 6 mm such that upon withdrawal from the layers well-defined, straight, cylindrical holes, bores or channels 51 of substantially the same diameter remain in the liner 13, the channels 51 extending through the top sheet layer 30, through the absorbent core layer 50 and partially through the moisture barrier layer 34. The channels 51 allow moisture to pass directly into the interior of the absorbent core layer 50 to be absorbed laterally by the interior and lower portion of the absorbent core layer 50. This greatly increases the absorption efficiency of the core layer 50 since moisture is now absorbed directly into the interior of the core layer 50 through the channels 51 in addition to being absorbed directly through the upper surface of the absorbent core layer 50. Furthermore, the channels 51 increase the evaporation rate of moisture from the liner 13 when the headwear 12 is removed. With the dimensions not meant to be limiting, providing rows of channels 51 spaced approximately 0.25 inches apart, with the channels being spaced approximately 0.25 inches in each row, has been found to be a suitable and efficient distribution.

In an alternative embodiment shown in FIG. 2, the liner 13 comprises a topsheet layer 30, absorbent core layer 50 and moisture barrier layer 34 non-adhesively joined together into a layered assembly, the assembly possessing channels 51 as previously described. A double-sided tape is joined to the underside of the moisture barrier layer 37, the double-sided tape comprising a carrier layer 37, which may comprise for example a paper or polymer film layer, sandwiched between two adhesive layers 35. The carrier layer 37 may be composed of a material that is impermeable to liquid, moisture or moisture vapor. As in the earlier embodiment, the release layer 36 is temporarily applied to the bottom adhesive layer 35 and removed prior to affixation of the liner 13 to the interior band 10 of the headwear 12.

Still another embodiment is illustrated in FIG. 3, where the liner 13 comprises a topsheet layer 30 and absorbent core layer 50 non-adhesively joined together into a layered assembly, the assembly possessing channels 51 that extend through the topsheet layer 30 and the absorbent core layer 50. The moisture barrier layer 34 is provided with adhesive layers 35 on its upper side and underside, such that the moisture barrier layer 34 is adhesively bonded to the underside of the absorbent core layer 50. As in the earlier embodiments, the release layer 36 is temporarily applied to the bottom adhesive layer 35 and removed prior to affixation of the liner 13 to the interior band 10 of the headwear 12.

FIGS. 5A and 5B show an embodiment for the liner 13 that enables the liner 13 to also be used as a headband without affixing it to headwear. The free ends of the liner 13 are provided with hook-and-loop type fastener elements 19, with one hook-and-loop component attached to the top of the liner 13 and the other hook-and-loop component attached to the bottom of the liner 13. With this construction, the liner 13 may be joined to itself to form a complete annular band which can be worn on the user's head. The release layer 36 may be provided with printed indicia, such as team logos, brand names, slogans, etc.

The liner 13 may be provided with anti-microbial agents, coloring, designs, textures, temperature- or moisture-sensitive inks that react to heat and moisture when the liner 13 is worn, cooling agents, etc. The release layer 36 may be provided with tabs, slits to enable easier removal of the release layer 36 from the adhesive layer 35, and may extend slightly beyond one or both ends of the adhesive layer 35. The adhesive layer 35 may be discontinuous or not fully coextensive with the underside of the moisture barrier layer 34. Magnets may be incorporated into the liner 13 to improve concentration.

It is understood that equivalents and substitutions for elements set forth above may be obvious to those of ordinary skill in the art, and therefore the true scope and definition of the invention is to be as set forth in the following claims. 

I claim:
 1. A self-adhering, disposable headwear liner comprising: a topsheet layer joined to an absorbent core layer; a moisture barrier layer joined to said absorbent core layer; an adhesive layer joined to said moisture barrier layer; and a plurality of straight channels extending through said topsheet layer and said absorbent core layer.
 2. The headwear liner of claim 1, wherein said straight channels extend partially into said moisture barrier layer.
 3. The headwear liner of claim 1, further comprising a release layer removable joined to said adhesive layer.
 4. The headwear liner of claim 1, wherein said topsheet layer, said absorbent core layer and said moisture barrier layer are non-adhesively joined.
 5. The headwear liner of claim 1, wherein said topsheet layer, said absorbent core layer and said moisture barrier layer are mechanically joined by punch-bonding.
 6. The headwear liner of claim 1, wherein said topsheet layer, said absorbent core layer and said moisture barrier layer each comprise fibers and said fibers of adjacent layers are mechanically interlocked to join said topsheet layer to said absorbent core layer and said absorbent core layer to said moisture barrier layer.
 7. The headwear liner of claim 1, wherein said channels are cylindrical.
 8. The headwear liner of claim 1, wherein said channels are formed by punch-bonding.
 9. The headwear liner of claim 1, wherein said moisture barrier layer is joined to said absorbent core layer by an additional adhesive layer.
 10. The headwear liner of claim 1, further comprising a carrier layer joined to said adhesive layer and an additional adhesive layer joined to said carrier layer.
 11. The headwear liner of claim 1, further comprising hook-and-loop type fasteners, wherein said liner is attachable to itself to form an annular band.
 12. The headwear liner of claim 1, wherein said channels are approximately 2 mm to 6 mm in diameter.
 13. A self-adhering, disposable headwear liner comprising: a topsheet layer non-adhesively joined to an absorbent core layer; a moisture barrier layer non-adhesively joined to said absorbent core layer; an adhesive layer joined to said moisture barrier layer; a release layer joined to said adhesive layer; and a plurality of straight channels extending through said topsheet layer and said absorbent core layer and extending partially into said moisture barrier layer.
 14. The headwear liner of claim 13, wherein said topsheet layer, said absorbent core layer and said moisture barrier layer are mechanically joined by punch-bonding.
 15. The headwear liner of claim 13, wherein said topsheet layer, said absorbent core layer and said moisture barrier layer each comprise fibers and said fibers of adjacent layers are mechanically interlocked to join said topsheet layer to said absorbent core layer and said absorbent core layer to said moisture barrier layer.
 16. The headwear liner of claim 13, wherein said channels are cylindrical.
 17. The headwear liner of claim 13, wherein said channels are formed by punch-bonding.
 18. The headwear liner of claim 13, wherein said channels are approximately 2 mm to 6 mm in diameter.
 19. A self-adhering, disposable headwear liner comprising: a topsheet layer non-adhesively joined to an absorbent core layer; a moisture barrier layer non-adhesively joined to said absorbent core layer; wherein said topsheet layer, said absorbent core layer and said moisture barrier layer each comprise fibers and said fibers of adjacent layers are mechanically interlocked to join said topsheet layer to said absorbent core layer and said absorbent core layer to said moisture barrier layer; an adhesive layer joined to said moisture barrier layer; a release layer joined to said adhesive layer; and a plurality of straight channels extending through said topsheet layer and said absorbent core layer and extending partially into said moisture barrier layer, wherein said channels are approximately 2 mm to 6 mm in diameter.
 20. The headwear liner of claim 19, wherein said topsheet layer, said absorbent core layer and said moisture barrier layer are joined by punch-bonding. 